Electric welding apparatus



Dec. 1,1936. I H. G. WARNKE 2,032,849

ELECTRIC WELDING APPARATUS Filed Nov. 12, 1934 4-Sheets-Sheet 1 INVENTOR Hans G. War/7 Ae BY W M v ATTORNEY-s 4 Sheets-Sheet 2 ATTORNEYS H, e. WARNKE ELECTRIC WELDING APPARATUS Filed Nov. 12, 1954 Dec. 1, 1936. H. a. WARNKE ELECTRIC WELDING APPARATUS Filed Nov. 12, 1934 4 Sheets-Sheet 3 ATTORNEY-5' l, 1936. H. G. WARNKE ELECTRIC WELDING APPARATUS Filed Nov 12, 1934 4 Sheets-Sheet 4 INVENTQF Hans G.War-nke ATTORNEY I l UNITED;

' ratus of =that which a'plurality of ;weld-' Patented Dec. 1; 1936' T O FICE Hans :Mglti-Hydmmaflc" Welding &'

I D IsLD LQM ch a-corporaflon The meshes-sate to'electricwelding meing units; individually positioned in a predetermined relationto each-other and to the work. are automatically operatedfrom .a control unit fle'ret'ofore apparatus ofthis gen eral been devised in which the individu'al welding 'units are succesively hydrauliecally operatedtojpress-the electrode against the work and'to f'supply electrical 7 current thereto.'":

The successive operation is accomplished through themovement of a traveler in conjunction with a series of. valvesand electric switches successively actuated thereby. The timingof the operation is determined by the speed of the traveler which in turn is controlled by the velocity of movement,

of its actuating-mechanism. Thus where this mechanism is moved at constant speed, the successive welding operations will he'the same, both as to the interval ottime in which pressure isapp ied to the electrode and the portion thereof "during which current is supplied therethrough.

However,. for. certain kinds of work requiringa series of welds, it is desirable to use welding units of a somewhat different character and which require different time intervals for the successful performance of, their functions, or a larger or smaller current volume. It is-therefore one of the objects of the present invention toobtain a construction of control mechanism in which the timing of operation of the successive welding units may be varied as desired, while still maintaining the automatic sequential operation. It is' a further object to more accurately determine the relative length of time during which the electrode is pressed against the work and the electric current supplied thereto. Still further it is an object-to provide means for varying the volume of current which is supplied through one electrode .with respect to that supplied through other electrodes. with these and other objects in view the invention consists, first, in the novel construction of the automatic control unit, and second,

in various specific features of construction as' hereinafter setforth.

In the drawings:

Fig. 1 is a diagrammatic view of a multiple electric welding apparatus to which my improved control unit is applied;

' Fig. 2 is a plan view; of the control unit;

Fig. 3 is a side elevation thereof; 1

Fig. 4 is a cross section on line H,- Fig. 2;

Fig. 5 is an end elevation; I

Fig. .6 is a view similar to a portion of Fig. 3' showing a'modifled-construction;

(ans-f4) s r'igfiisasectionalendelevationthereoh" Fig.8'isaviewsimilartor'lg.6showinganother -m d fl t cn:

is'an'endelevation-thereof. Fig. isa diagrams'imilartoaporticnof Fig.

l-showing a'modiiied constmctiomfl Fig. 11'is an enlarged sectional elevation of on .of the valves'an'd electric circuit closers together with. itsactuating' 1E. l

The specific construction of the individual l' e sn tf s sn al t e-P s i .vention, butiin general eachpf' these units comprises an hydraulic cylinder;A containing a piston B, a piston rod C -and' an electrode D connected with the lower end 'of The cylinder A is to a suitable bracket .E which is mounted in "predetermined relation to a jig (not-shown) 'for supporting the work. Electrical current is supplied to "'oi' the. electrodes through flexible conductor-sq attached to'a supply conductorH and a return conductor I'isarranged beneath the work and supports the same.

The conductors H and-I are connected to secondary leads from atransformer'J which supplies current at the desired voltage.

My improved controller may be arranged in any desired relation to the, jig and welding units mounted thereon, and is ofth'e following construction:

K are control units each adapted to control a predetermined number of welding units such for instance as ten, and these control units are adapted for mounting in series with each other in any desired number. Each unit comprises a rectangular block which is longitudinally aper tured at K, K for the passage of clamping rods L extending the entire length of the series. At opposite ends of the series are heads, L and L which are also apertured in alignment with the apertures K, K for the passage of the rods L. Nuts 1.. engaging threaded ends of the rods Lserve to clamp all of the units and the heads in rigid relation to each other.

As above stated, each unit K controls a pmrality of welder units and to this end the block is provided with cylindrical bores K preferably arranged in two series inparallel vertical planes extending longitudinally of the block on opposite sides of the center thereof. Each bore has connected thereto a transverse bore K threaded for engagement with a coupling M which'connects it with a flexible conduit M'leading to the cylinder A of the particular welding unit to be controlled.

There are also bores-K extending transversely of the corresponding cylinders K of the two series. These bores also intersect a central longitudinally extending passage K and the outer end of each bore K is stopped by a plug K". The passages K in the several units all register with each other and serve as a fluid supply connection extending from a .suitabie source of'fluid under pressure to each of the cylinders of both series,

In each of the cylinders K is a piston N slidably fitting the same and provided with a reduced portion N which forms therearmind an annular fluid channel N. This channel communicates with the transverse bore K so .that'fluid' from the passage K is always in communication with said annular channel. In the normal'po'sition of each piston a head N at the lower end thereof is raised above the passage K- so as to cut-oi: commun ication from the channel N. However, when the piston is depressed, the head N will pass below the passage K, which. establishes communication between-said passage 'and the channel N and also with the supply conduit K; The piston is held normally in raised position by a spring N surrounding-a reduced shank N which depends from the head N and passes through an aperture in a plate K secured to the lower face of the block K, said plate forming an abutment for the lower end of each spring, N. Upward movement of the piston under theresilient pressure of the spring is limited by a nut N enga ing a threaded portion of the stem N. There is also a lock nut N" threadedly engaging the stem and,

carrying at its lower end a spring pressedelectrical contact N. f

The head-L at one. end of the series has an upwardly extending portionL, and the head L a at the opposite end has the outward extension L and an upward extension L.

other by a pairof spaced parallel rods 0, O and parallel to these rods is a screw threaded shaft 0 which at one end is journaled in a bearingin the upwardly extending portion L, and at its opposite end is coupled to a rotary air moi'orPby means of which itis revolved. As this air motor may be of any suitable construction, Ihave merely shown thesame in elevation as mounted upon the .outward extension L of the head L, being suitably adjusted in alignment with the shaft 0 by screws P. At the upper end of the portion L is mounted a control valve P by means of which the direction of rotation of the motor P may be reversed, as will be hereinafter set forth. Q is a traveler slidably mounted upon the parallel rods 0, O' and having a nut. engaged with the threaded shaft 0 by which it is caused to move from one end to the other, depending upon the direction of rotation of the motor. The traveler is also provided with means for operating the reversing valve P for the rotary motor P so that after traveling to one end of the screw threaded shaft, its, direction will be reversed to travel back to the opposite end, where its movement is arrested. This reversing mechanism includes a stem P for the reversing said groove engaging the nose piece P will hold the valve in the reverse position against the tension of the spring P. R'is a rod slidably engagmove the carriage Q towards the head L.

. Thefportions L" and L are longitudinally connected with each [aperture in said post and being threaded for engagement with nuts Q by which it is adjustably secured in position.- The trip rod Q extends parallel to the screwand in axial alignment with the pin" 13. against which it abuts when the traveler Q is at the. end of the screw adjacent to the when the carriage Q is adjacent to the bearin L the valve P will. be in neutral position where the motor .1 is at rest. To start operation, the

rod Rand arm R are manually moved so as to actuate the stem P, moving the valve P to a po- I sition where the latch P" engages the groove P. In this position movement is imparted to the motor P in a direction to cause the screw 0 to As the traveler approaches said head the trip rod Q will engage the bell crank arm of the latch P", releasing said latch from the groove P and permitting the spring P to move the valve into reversing position.

v engages the pin Rit will move this pin, rod R the length of thescrew O and will return to its original position.

Mounted upon the traveler Q are'a transverse series of mckable cam members'S, S, S and S. These are detachably secured in position by engaging slots in the frame of the traveler and pivotally engage pins S and S which extend transversely to said slots through-apertures in the cams. The ends of the pins S and S have threaded portions S engaging correspondingly threaded portions of the bores and with polygonal heads S". This permits of quickly detaching the pins whenever it is desired to exchange the cams. The cams S and S are respectively in alignment with the two series of pistons N on opposite sides of the center of the blocks K, so that during movement of the traveler said cams will successively engage the upper ends of said pistons. The constructionis, however, such that during movement 'of the traveler in one direction as from the head L towards the head L, .the cam S will successively operate the valves in alignment therewith while the cam S will rock so as to pass over the other series of valves without actuation of the same. On the other hand, when the traveler is moved in the opposite direction from the head L towards the head L, the cams S' will successively operate the valves aligned therewith while the cam S will rock to pass over its valves without operation and the other half during its movement in the reverse direction. The cams S and S are similar in construction but are reverseiy positioned in relation to the traveler Q sojthat one will operate when the traveler is moving in one direction and the other when the traveler is moving in the reverse direction.

when operating, each of' the cams will successively depress the piston valves N during movement of the traveler and this as before described will open the port supplying hydraulic fluid to the corresponding welder: unit'through the connecting conduit M. ,In additionito the function of controlling the hydraulic fluid for depressing the electrode of the welding unit, each of the valves N performs-the additional function of closing an electric circuit controlling the supplying of current to said electrode. To this end the lower end of the shank of the p'istonvalve is provided with a contact pin N, previousl described, which is adapted to connect with a coopcrating adjustable contact member when the valve piston is fully depressed by the cam. The cooperating contact members T for the valves of the series are mounted upon a supporting bar'T' which extends beneath the units K- and is secured to depending portions L and L respectively on the heads L and L by means of clamping adjustment the contact member T is threaded and engages a correspondingly threaded aperture in the bar T, being provided with a polygonal head T and a "locknutT for holding the contact in adjusted position. With the con-' struction as shown in Fig. 2, the-bar T is metallie and forms a part of the electrical circuit; It is therefore necessaryjto insulate this bar from its supports and as shown, bushings T surround the clamping bolts L where they pass through the bar T' and insulator washers T are placed betweenthe bar and its supports and also between the bar and the screws L. This construc-- tion is used where the'current supplied to the,

vided with a shoulder portion S'- at one side of v the pivot pin for bearing against the top wall S .of the slot in whichthe cam is located-thereby limiting the rocking movement of the cam-in one direction. S .isthe nose portion of the cam for engaging with the valves N which has an oblique portion S for first depressingthe valve, a step 8' for holding the valve in a position where the fluid port is open, but before the electrical contact N'is closed with the cooperating contact T, a portion S for further depressing the valve and closing the electric circuit through engagement of the contact N with the contact T and a portion 8' which opens the circuit but still holds the port open'whichsupplies pressure to the electrode. By this arrangement it will be understood that the electrode D is moved in contact with the work and pressed thereagainst in advance of supplying electrical current, and after g cutting oh the {current the electrode is still pressed against the work for a brief time interval. The exact timing of the interval in which current is supplied may be varied,by adjusting the contact. member T in 'its'screw threaded bearing which enables the operator to obtain the best eflect.

With the apparatus as thus far described, the cams S and ',-will operate the same oneach of the valve pistonsNsothat the welding units controlled by said-valves-wili be operated all alike.

However, asabove stated, it'is frequently desirable to vary the cited; produced by different welding units, which may be accomplished either by changing the time interval during which current is supplied or by changing the volume of current supplied during the interval. For preducing the first efiect, I have provided means for varying the speedof rotation of the motor P, this producing 'corre'sponding change. in the speed of movement of the traveler and the length of time in which the cam is operating on the valve. As the motor P is operated by compressed air, its speed may be regulated by variably throt-' tling the air supphr; However, this throttle must be properly timed with the movement of the traveler over the cams, which is accomplished by the following construction: It has been stated that in addition-to the cams S and '8' there are two other cams Sy' and Slwhich are pivotally supported on the pins 8 and 8 These cams S and S cooperate with a series of 'rock arms U which are'connected to rock shafts U' and W arranged on opposite sides of the blocks K. The shafts vU and mare iournaled in brackets U detachably'connected to the heads L and L so that whenever it is desired to change the number of rocker arms on these shafts, they may be quickly detached -for that purpose. Each rocker arm U has a bifurcated portion 11 with the furcationsthereofapertured for sliding engagement upon the shaft U and U Between.

At one end of each shaft U and U is secured -a rocker arm U Ywhich is adapted during the rocking movement of the shaft to operate a throttle valve controlling the air supplied to the motor P. As shown, two of such throttle valves 'Vand V' are arranged on opposite sides of the head I and each is adapted to restrict the air flow independently of the other. The valves V and V are pistons siidably secured in cylinders respectively in the valve casings W and V being urged upward by springs V arranged" within these housings and being moved downward by the rocker arms U. The valves may be of any suitable construction such as having an annular groove V in the piston permitting pas sage of air between ports V and V" on diametrically opposite sides of the valve casing. The ports W of the two valve casingsV and V? are connected to each other by a passage V through the head 1.. so that the two valves are in series with each other. Air is supplied to the casing V is connected by a conduit V" with the inlet of the valve casing P. It will thus be understood depressed by the operation of its corresponding rock arm U it will restrict the flow of air which is supplied to the valve casing P and the amount of restriction corresponds to the degreeof do pression of the valve. This in turn depends upon the angular movement of the rock-shaftU' or U which may be varied by the adjustment of the rocker arms -U. Thus where it is desired to increase the time of operation of one or-more of the welderunits one of the rock arms U-is adjusted into transverse .alignment with-the valve N which controls this particular unit, and is secured in this position by clamping the split col-.

lar to'the rock shaft by means of a screw U".

The rock arm is-then-angularly adjusted to thedesired degree by means of the screw U When; properly adjusted, one of the throttle valves V or V will be operated to slow the rotary motor T while it is moving the traveler Q and 'cam S or S over the corresponding valve N. Consequently the interval during which the .valve is depressed is lengthened which correspondingly lengthens the interval during which the-electrode is pressed against the work and that during which current is supplied.

Where there are several; welder .units which require thesame timing, these may all be controlled by a single rocker arm U on the shaft U by providing such arm with a bridge member U may be. extended to, anylength to correspond) with the desired number of valves N controlling the said welder units and thus thecam S or S will hold the rock arm depressed while the traveler is passing all of 'said' valves. This sim plifies the construction, as it avoids the necessity of individual rock arms U for each of the welders pairs of conductor bars Y and Y, which prefer.-'

ably extend the entire length of the bar and are spaced from each other to be out of electrical connection. One of the bars Y is connected into an electrical circuit for controlling a transformer supplying current at low voltage, and the other bar Y is similarly connected into a circuit controlling a transformer for supplying current at higher voltage. These control circuits are completed through the individual contact members Y, each of which is electrically connected either to the bar Y or the bar Y by means of transversely extending connectors Y. These extend through transverse bores in the bar Y and are preferably formed of a headed bushing member Y threadedly engaging the bars Y or Y and a contact pin Y passing through said bushing having a head Y for contacting with the member Y and with a spring Y between said head and .the bushing Y for maintaining contact. With this construction all of the welder units which re- 'quire a large current volume have their contacts Y connected to the bar Y while those using a lesser volume of currents have their contacts Y connected to the bar T'.

from a conduit W and the .port V of the casing V? y connecting with the bars Y. Further variation may be accomplished by varying'tlie speed of the traveler as before described.

that when either one ofthe'. valves V and V .Where there are only a few of the welder units Q T and contacts T previously described and mount upon this bar an insulator block W. Ad-

justable-contacts W' similar to the contacts T are threadedly engaged with this block and pass through enlarged apertures W in the bar T' so as to be out of electrical connection therewith.

Transversely extending connectors W similar in construction to the connectors Y connect the circuits connected to the bar Y while those requiring less current have their control circuits The construction of the automatic control being as above described, theoperation is as follows The individual welder units are first mounted on a jig in predetermined relation tothe work to be supported thereon, as has been previously described; The automatic control is then coupled to the welder units by means of the flex,- ible conduits M so that the welders are operated in the desired sequence. -To expedite the work twojig's may be employed, the welders of one being controlled by one series in the controller and the other by the second series. In this way the operator may utilize the time during which the work in one jig is being welded for removing the completed work from the other jig and engaging new work to be welded.

When the control is properly coupled to the weldersv it is supplied with compressed air and liquid-under the desired hydraulic pressure from any. suitable source.- Preferably the pump for v supplying hydraulic pressure is incorporated as a part of the control unit, but asthisforms no part -of the present invention it is not illustrated or described, as it is-obvious that the operation will be the same, whatever the source of such liquid under pressure. The electrical circuits are illustrated in F1 s. land 10 'In the former the bar T' is used, ing connected by a conductor X with a relay X which operates the circuit closer, X for the primary coil J of the transformer J. .As previously stated,- the secondary coil J? of this transformer is connected-to the conductors H and I for the welder units. With the construction illustrated in Fig, 10, the substitute bar Y.

'or different steps of the same transformer. Thus as shown, the bar Y is connected by a conductor X to a relay X controlllngthe circuit closer X for the primary of a low voltage transformer "all oflthe welder units which are supplied with a larger volume of current have their-control.

J The bar Y is similarly connected through-a I conductor")! with a relay X controlling a clrcuit closer X for the primary of a higher voltage transformer J. The secondary circuits of the transformers J and J are alternatively conenin'g a set screw fl 'in thecollar U and sliding 4 -said collar along its'shaft U or (I to the desired position and then again tightening the set screw: Angular adjustment of the rocker arm U with respect to its shaft is then made by the adjust- 5 ing screw U, this determining the amplitude of movement of the throttle valve V or V and consequently its throttling eiiect.

when all adjustments have been properly made; operation is started by the manual manipulation of the valve stem P which as previously described starts the motor P in a direction to cause movement of the traveler from the head 1 L towards the head L. Dining this movement the cam- S will successively depress the piston valves N which'flrst press the corresponding ele'ctrodes against the work and then supp y them with current, -Each oneof the rocker arms'U is positioned in registration with a particular piston valve so that during theinterval in which said valve is depressed the rocker arm U will also be depressed. Thus the valve V or V' will be positionedto restrict the admission of air to the motor P, thereby slowing its speed and correspondingly slowing movement of the traveler.

2 As soon asthe cam 8* or S on the traveler disengages from the rocker arm U, the spring V will raise the throttlewhich will restore full speed to the motor P and the traveler Q.

when the machineds adjusted as shown in Fig. 10, thevolume of current supplied to the. individual welders may be varied depending p n whether their controi circuits are coupled to the bar Y or the bar Y Thus an increased heating effect may be produced either by slowing the motor P to lengthen the time interval or by increasing the volta'ge to enlarge the current volume or by a combination of both. This gives greatflexibility to the apparatus so that it may ,easily be adapted to meet any condition which so simultaneously therewith by said traveler so as to alter the length of the welding operation of the corresponding welding unit.

2. -In a welding machine, the combination with a series of individually operable welding units,

of a series of controls for the respective units.

' a traveler for operating said controls in sequence,

means for driving said traveler at a predetermined speed, means for progressively varying said ment thereof, a rock shaft for actuating saidspeed, a control for said speed varying means po- 'sitionable in'predetermined relation to a selected welding unit control to be operable simultaneously therewith by said traveler, and means for adjusting said speed control to change the magnitude of speed variation effected thereby as and to correspondingly vary the operation of the corresponding welding unit;

3. Ina welding machine, the combination with a series of individually operable welding units,

-speed of said drive mechanism, and controll g mechanism for said speed varying means comprising a rock shaft'extending longitudinally of a said frame parallel to the direction of movement of said traveler, a rock arm on said rock' shalt operatively connected to said speed varying 5 means. and a rock arm adjustable longitudinally of said rock shaft into predetermined relation to a selected welding control tobe operable simultaneously therewithby said traveler and tothereby alter the length of operation of the corre- 10 sponding welding unit,

4. In .a welding machine, the combination with a series of individually operable welding units, of a control unit therefor comprising a frame, a series-of controls for the respective units mount- 15 ed on said frame, a traveler movable on said frame and engageable with said controls to operate the same in sequence, a drive mechanism for said traveler, means for progressively, varying the speed of said drive mechanism and con- 2 trolling mechanism for said speed varying means comprising a rock shaft extending. longitudinally of said frame parallel to the direction of movement of said traveler, a rock arm on said rock shaft operatively connected to said speedvarying means, and a rock arm longitudinally adjustable on said rock shaftinto predetermined rela tion to a selected welding unit control to be operable simultaneously therewith by said traveler, and means for angularly adjusting said 30 rock arm to change the magnitude of speedvvariation and to correspondingly change the time of operation of the corresponding welding unit.

5. In a welding machine, the combination with a series of individually operable welding units, 35 of a series of controls for the respective units,

a traveler; for operating said controls in sequence.

.adjustingsaidrockarmandcamtochangethe.

amplitude of rocking movement and thereby change the variation in speed of the traveler.

, 6. In a welding machine, the combination with 50 a series of individually operable welding units,

- of a series of controls for the respective units,

each control including a depressible piston, a traveler moving parallel to said series of ,con-

trols, a cam carried by said traveler for successively depressing said piston, means for moving said traveler 'at a predetermined maximum speed, means for retarding the speed oi movepredetermined relation to a selected control, and

a second cam carried by said traveler in alignment'with said first cam for depressing said rock as arm and thereby slowing movement of said traveler while passing said control. 7. In a welding machine, the combination with a plurality of individually hydraulically operated welding units, of a series of controls therefor, each control comprising a depressible piston valve, means operated by the depression of said piston valve to a predetermined point for admitting fluid under pressure to the corresponding weldi g. unit, a circuit closer operated by a fur-jg ther depression of said piston valve. means for supplying welding currentto the welding units operated by said circuit closer, a traveler movable parallel to said series of controls and a cam carried by said traveler Ior successively depressing said piston valves, said cam having spaced steps for depressing said piston 'valve' to the point for hydraulically operating the welding unit without closing the electric'circuit, and-an having hydraulically operated pressure-'means,- of a plurality of means for supplying welding" current at.diflerent. voltages to which said unitsare alternatively connected, a series of controls for the respective units each including hydraulic pressure supplying means and an electric circuit closer, alternative electrical connections between the circuit closers of said controls and the respective welding current supplying means andmeans for operating said controls in sequence.

9. In a welding machine, the combination with a series of individually operable weldingunits, of

a series of controls iorthe respective units, a

v e r p t ns said controls infsequence a; f

7 traveler to alter the welding .a'ction ponding w ld unit.

and means for varying the welding action of said welding units when operatedby their respective ,10.-In a welding machine, the combination with .a series oi individually operable' welding units, oi. a series oiffcontrols for the respective units. a traveler-tor operating said'gcontrols in sequence, and means for varying the length of time of operation oi. said welding units when actuated by said controls.

11. In a weldingma i e, the combination with a series or individually operable welding units, 0! a series oi controls for the respective units, a traveler for operating said controls in "sequence, means positionable in predetermined relation to a selected welding unit controlto be operable simultaneously therewith by. said of the cor- 12. In a welding machine, the combination with a plurality of individual welding units, oil means for supplying welding current at different;

voltages,va series of controls for the respective units adapted to alternatively connect the high' or low voltage current-thereto, and means for operating said controls in -sequence.

HANS awsnnkny 

